U.S. patent number 6,237,644 [Application Number 09/333,227] was granted by the patent office on 2001-05-29 for tissue forming fabrics.
Invention is credited to James Loy Brewster, Stewart Lister Hay, Jeffrey Bruce Herman, Jan Strom.
United States Patent |
6,237,644 |
Hay , et al. |
May 29, 2001 |
Tissue forming fabrics
Abstract
A fabric employed in a web forming apparatus to form a patterned
fibrous web includes at least one layer of yarns oriented in first
and second directions and being woven to provide a lattice that
separates a plurality of systematically distributed woven areas of
a predetermined configuration that is defined by the pattern of the
continuous lattice and with the systematically distributed woven
areas including at least three yarns oriented in each of the first
and second directions.
Inventors: |
Hay; Stewart Lister (Bury BL0
9EH, GB), Brewster; James Loy (Waskom, TX),
Herman; Jeffrey Bruce (Bala Cynwyd, PA), Strom; Jan
(SE-610 40 Gusum, SE) |
Family
ID: |
26795253 |
Appl.
No.: |
09/333,227 |
Filed: |
June 15, 1999 |
Current U.S.
Class: |
139/383A;
139/383R |
Current CPC
Class: |
D21F
1/0027 (20130101); D21F 11/006 (20130101) |
Current International
Class: |
D21F
11/00 (20060101); D21F 1/00 (20060101); D03D
001/04 () |
Field of
Search: |
;139/383R,383A |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Calvert; John J.
Assistant Examiner: Muromoto, Jr.; Robert H.
Attorney, Agent or Firm: Caesar, Rivise, Bernstein, Cohen
& Pokotilow, Ltd.
Parent Case Text
RELATED APPLICATIONS
This application is based upon provisional application Ser. No.
60/098,913, entitled "Patterned Tissue Fabric" and filed on Sep. 1,
1998. Applicants claim the benefit of the filing date of that
application.
Claims
What we claim as the invention is:
1. A fabric employed in a web-forming apparatus to form a patterned
fibrous web, said fabric including a web-contacting surface for
engaging a fibrous web and assisting in imparting a pattern in said
web, said fabric including only a single layer of yarns oriented in
first and second directions and being woven to provide a lattice,
said lattice separating a plurality of systematically distributed
surface areas of a predetermined configuration that are defined by
the lattice; said systematically distributed surface areas
including at least three yarns oriented in each if said first and
second directions.
2. The fabric of claim 1, wherein the lattice is continuous.
3. The fabric of claim 1, wherein at least 75% of the yarns in the
lattice have a zero interlacing density.
4. The fabric of claim 1, wherein 100% of the yarns in the lattice
have a zero interlacing density.
5. The fabric of claim 1, wherein the lattice is discontinuous and
includes discrete segments separated from each other by
systematically distributed surface areas.
6. The fabric of claim 1, wherein the size of at least one of the
systematically distributed surface areas differs from the size of
at least another of said systematically distributed surface
areas.
7. The fabric of claim 1, wherein the yarn interlacing density of
at least one of the systematically distributed surface areas
differs from the yarn interlacing density of at least another of
said systematically distributed surface areas.
8. The fabric of claim 1, wherein the configuration of at least one
of the systematically distributed surface areas differs from, the
configuration of at least another of said systematically
distributed surface areas.
9. The fabric of claim 7, wherein at least one of said
systematically distributed surface areas utilizes a plain
weave.
10. The fabric of claim 1, wherein the weave pattern in the
systematically distributed surface areas is the same.
11. The fabric of claim 1, wherein the weave pattern in at least
one of the systematically distributed surface areas differs from
the weave pattern in at least another of said systematically
distributed surface areas.
12. The fabric of claim 1, wherein the interlacing density is zero
in each systematically distributed surface area.
13. The fabric of claim 1, wherein the interlacing density in each
systematically distributed surface area is greater than the
interlacing density in the lattice.
14. The fabric of claim 1, wherein the interlacing density in each
systematically distributed surface area is equal to the interlacing
density in the lattice.
15. The fabric of claim 1 being a forming wire in a wet forming
apparatus.
16. The fabric of claim 1 being a through-air drying fabric in a
wet forming apparatus.
17. The fabric of claim 1 being a transfer fabric in a wet forming
apparatus.
18. The fabric of claim 1 being a forming wire in a dry forming
apparatus.
19. The fabric of claim 1, wherein said systematically distributed
surface areas are predominately of a low yarn interlacing density;
being provided by successive yarns oriented in one of said first
and second directions floating over two or more successive yarns
oriented in the other of said first and second directions, adjacent
systematically distributed surface areas being separated by said
lattice.
20. The fabric of claim 1, wherein said systematically distributed
surface areas include an area therein wherein one or more of said
successive yarns oriented in said one of said first and second
directions interlaces with at least one yarn oriented in the other
of said first and second directions to thereby interrupt the
continuity of the yarn float over the yarns oriented in the other
of said first and second directions.
21. The fabric of claim 1, wherein said systematically distributed
surface areas include at least four successive yarns oriented in
each of said first and second directions.
22. The fabric of claim 1, wherein said systematically distributed
surface areas include sixteen successive yarns oriented in each of
said first and second directions.
23. The fabric of claim 1, wherein said systematically distributed
surface areas include eight successive yarns in one of said first
and second directions and seven successive yarns in the other of
said first and second directions.
24. The fabric of claim 1, wherein said systematically distributed
surface areas include eight successive yarns in one of said first
and second directions and eight successive yarns in the other of
said first and second directions.
25. A fabric employed in a web forming apparatus to form a
patterned fibrous web, said fabric including a web-contacting
surface for engaging a fibrous web and assisting in imparting a
pattern in said web, said fabric including only a single layer of
yarns oriented in first and second directions and being woven to
provide systematically distributed surface areas having a
predetermined configuration, said systematically distributed
surface areas being provided by successive yarns oriented in one of
said first and second directions floating over two or more
successive yarns oriented in the other of said first and second
directions, adjacent systematically distributed surface areas being
separated by a region wherein said successive yarns oriented in
said one of said first and second directions float under one or
more successive yarns oriented in the other of said first and
second directions with the ends of said latter floats defining
marginal edges of said adjacent systematically distributed
areas.
26. The fabric of claim 25 being a forming wire in a wet forming
apparatus.
27. The fabric of claim 25 being a through-air drying fabric in a
wet forming apparatus.
28. The fabric of claim 25 being a transfer fabric in a wet forming
apparatus.
29. The fabric of claim 25 being a forming wire in a dry forming
apparatus.
30. The fabric of claim 25 wherein said yarns oriented in said one
of said first and second directions are weft yarns and the yarns
oriented in the other of said first and second directions are warp
yarns.
31. The fabric of claim 25 wherein said systematically distributed
surface areas include an area therein wherein one or more of said
successive yarns oriented in said one of said first and second
directions interlaces with at least one yarn oriented in the other
of said first and second directions to thereby interrupt the
continuity of the yarn float over the yarns oriented in said other
of said first and second directions.
32. The fabric of claim 25 wherein each of said systematically
distributed surface regions are provided by at least four
successive yarns oriented in each of said first and second
directions.
33. The fabric of claim 25 wherein each of said systematically
distributed surface areas include sixteen successive yarns oriented
in each of said first and second directions.
34. The fabric of claim 25 wherein each of said systematically
distributed surface areas include eight successive yarns in one of
said first and second directions and seven successive yarns in the
other of said first and second directions.
35. The fabric of claim 25 wherein each of said systematically
distributed surface include eight successive yarns in one of said
first and second directions and eight successive yarns in the other
of said first and second directions.
36. A fabric employed in a web forming apparatus to form a
patterned fibrous web, said fabric including a web-contacting
surface for engaging a fibrous web and assisting in imparting a
pattern in said web, said fabric including only a single layer of
yarns oriented in first and second directions and being woven to
provide systematically distributed areas of a predetermined
configuration, said systematicallydistributed areas being provided
by successive yarns oriented in the first direction floating over
two or more successive yarns oriented in the second direction on
the surface of the fabric employed to engage the fibrous web,
adjacent systematically distributed regions being separated by a
region wherein said successive yarns oriented in said first
direction float under one or more successive yarns oriented in said
second direction, said one or more successive yarns oriented in
said second direction separating said adjacent systematically
distributed regions.
37. A fabric employed in a web forming apparatus to form a
patterned fibrous web, said fabric including a web-contacting
surface for engaging a fibrous web and assisting in imparting a
pattern in said web, said fabric including only a single layer of
yarns oriented in first and second directions and being woven to
provide a lattice arrangement, said lattice arrangement separating
a plurality of systematically distributed surface areas of a
configuration that is defined by the lattice arrangement; said
systematically distributed surface areas including at least three
yarns oriented in each of said first and second directions, the
lattice arrangement including yarns of said systematically
distributed surface areas, those yarns that are in both the lattice
arrangement and in said systematically distributed surface areas
having an interlacing density in said systematically distributed
surface areas that is greater than or equal to the interlacing
density in said lattice arrangement.
38. The fabric of claim 34 wherein those yarns that are in both the
lattice arrangement and in said systematically distributed surface
areas having an interlacing density in said systematically
distributed surface areas that is greater than the interlacing
density in said lattice arrangement.
Description
FIELD OF THE INVENTION
This invention relates to fabrics for use in making patterned paper
(e.g., tissue, towel stock and other wet formed cellulosic sheets)
or nonwoven materials, and which are especially suitable for use as
forming wires, transfer fabrics and dryer fabrics, particularly
through-air-dryer (TAD) fabrics in tissue making machines.
The fabrics are intended primarily for use in wet forming
processes, but may also be used for dry forming methods, e.g.,
wherein fibers are air-laid onto the fabric. Reference throughout
this application to "wet forming processes" or "wet forming
apparatus" refers to a complete web forming process or apparatus,
respectively, which may include the patterning, transferring,
drying and creping of an initially laid slurry of fibers from a
head box or other delivery device or system onto a forming
wire.
The structure of the fabric may be used to form patterns in the wet
or dry formed sheet by shaping the sheet and/or by influencing the
density or thickness of fiber deposits in a controlled manner.
BACKGROUND ART
Kimberly-Clark publication WO-96/35018 describes the formation of
patterns in a paper or tissue sheet using additional structures on
the surface of a woven fabric. The imprint in this case is caused
by providing systematically distributed areas of restricted
drainage in the fabric. As disclosed in the publication, the
drainage may be impeded by incorporation of additional filaments or
fibers on top of or within the forming fabric weave pattern, or by
a film or coating which blocks or fills void space within the
fabric through which water could otherwise drain. Over the areas of
impeded drainage, a thinner layer of relatively long fibers tends
to be deposited, whilst shorter fibers migrate and are concentrated
in the areas of more rapid drainage producing a thicker, less
translucent tissue over the faster drainage areas.
Gusums Bruk AB Swedish Patent 427,053 discloses a forming fabric
structure wherein areas of different density are created by
providing relatively dense areas wherein there is a high frequency
of yarn interweavings, and relatively porous regions wherein there
is a low frequency of yarn interweavings, which are dominated by
weft floats. In certain disclosed embodiments the areas of low
frequency interweavings provide physically raised areas that shape
the tissue.
Chiu U.S. Pat. No. 5,429,686 discloses a TAD fabric with a distinct
load-bearing woven fabric layer and an additional sculpture layer
formed by additional long-floated machine direction yarns, with the
floats standing proud of the main body of the load-bearing fabric
layer to shape the formed sheet.
OBJECTS OF THE INVENTION
It is a general object of this invention to provide forming
fabrics, transfer fabrics or dryer fabrics, particularly TAD
fabrics, for use in forming paper (e.g., tissue, towel stock and
other wet formed cellulosic sheets) or nonwoven sheet materials
having an improved embossed or patterned structure.
It is another object of this invention to provide forming fabrics,
transfer fabrics or dryer fabrics, particularly TAD fabrics, for
use especially in a tissue making machine to form improved embossed
or patterned tissue products.
It is another object of this invention to employ a forming,
transfer or dryer fabric in a web forming apparatus to form a
patterned fibrous web having a desired balance of properties and a
cloth-like appearance and texture.
It is another object of this invention to provide a web shaping or
embossing woven fabric without the incorporation of additional
filaments or other structures therein.
It is yet another object of this invention to provide a web shaping
or embossing woven fabric without the need to employ additional
processing steps to introduce additional elements into the woven
fabric structure.
SUMMARY OF THE INVENTION
The above and other objects of this invention are achieved by
fabrics employed as forming, transfer or dryer fabrics in web
forming apparatus, said fabrics being employed in making embossed
or patterned fibrous web products, such as paper (e.g., tissue,
towel stock and other wet formed cellulosic sheets) or non wovens.
The fabrics of this invention comprise both single and multi-layer
woven structures.
In accordance with preferred embodiments of this invention, the
fabrics include at least one layer of yarns oriented in both first
and second directions, said yarns being woven to provide a lattice,
said lattice defining marginal edges of adjacent systematically
distributed surface areas, with the distribution pattern,
configuration and dimensions of said adjacent surface areas being
dictated by the pattern of the lattice. The systematically
distributed surface areas, which can, but are not required to be of
the same configuration, weave pattern and/or dimensions, preferably
include at least three yarns oriented in each of said first and
second directions, and more preferably include at least four yarns
oriented in each of said first and second directions.
In accordance with certain aspects of this invention, each yarn
that is in both the lattice and in one or more systematically
distributed surface areas defined by the lattice has an interlacing
density in the lattice that is less than or equal to the
interlacing density of that yarn in the systematically distributed
surface areas. In connection with these aspects of the invention,
the lattice most preferably is, but is not required to be within
the definition of "lattice" set forth hereinafter. Throughout this
application, applicants, when they do not intend to be limited to
the definition of "lattice" set forth hereinafter, will refer to
"lattice arrangement." However, the "lattice arrangement," like the
"lattice," is required to define, or provide, marginal edges of
adjacent systematically distributed surface areas.
In other aspects of this invention, wherein a yarn located in both
the lattice and in one or more systematically distributed areas has
an interlacing density in the lattice that is greater than the
interlacing density in said one or more of the systematically
distributed areas, the lattice must meet the definition of
"lattice" set forth hereinafter.
The "lattice," which is of a chain link-like construction, in
addition to defining marginal edges of adjacent systematically
distributed surface areas, unless more specifically limited, means
a weave pattern in which, in the fabric surface adjacent the formed
sheet (hereinafter referred to as "the forming surface") more than
50% of the yarns defining the marginal edges of adjacent,
systematically distributed areas have a zero interlacing density
and wherein either all of the warp yarns or all of the weft yarns
float over one, or continuously over more than one weft yarn or
warp yarn, respectively, to form either a chain link-like array of
warp floats or a chain link-like array of weft floats throughout
the fabric on the forming surface; wherein when an array of warp
floats is formed throughout the forming surface each warp float in
the array either floats over the same weft yarn and/or over one or
more adjacent weft yarns as adjacent warp floats in the array, and
when an array of weft floats is formed throughout the forming
surface each weft float in the array either floats over the same
warp yarn and/or over one or more adjacent warp yarns as adjacent
weft floats in the array.
More preferably, more than 75% of the yarns in the lattice that
define the marginal edges of adjacent, systematically distributed
areas have a zero interlacing density and most preferably 100% of
such yarns have a zero interlacing density.
Reference to "zero interlacing density" in the lattice means that
the warp or weft yarns that float over one or more weft yarns or
warp yarns, respectively, remain on the forming surface and move
out of the forming surface only at the perimeter of adjacent
systematically distributed surface areas to define marginal edge
segments of said areas.
Most preferably the lattice is "continuous" throughout the fabric,
i.e., it defines the marginal edges of the systematically
distributed areas about the entire perimeter of such areas.
To further explain, the lattice, which, as stated above, preferably
is continuous, can be formed either by an array of warp floats of
all of the warp yarns over one or more weft yarns, or alternatively
by an array of weft floats of all of the weft yarns over one or
more warp yarns. In the former case, each warp float in the array
either floats over the same weft yarn and/or over one or more
adjacent weft yarns as adjacent warp floats in the array. In the
latter case, each weft float in the array either floats over the
same warp yarn and/or over one or more adjacent warp yarns as
adjacent weft floats in the array.
In certain preferred constructions, the lattice is continuous and
is provided either by an array of warp floats in which each of the
warp yarns floats over more than one weft yarn, or by an array of
weft floats in which each of the weft yarns floats over more than
one warp yarn, and wherein adjacent warp or weft floats provided by
adjacent warp or weft yarns, respectively, at least partially
overlap each other. That is, the adjacent warp or weft floats
extend, or float over at least one weft or warp yarn, respectively,
that is the same, and, if desired, over one or more adjacent weft
or warp yarns.
Thus, in accordance with preferred embodiments of this invention,
adjacent systematically distributed areas are separated by a
continuous lattice wherein yarns oriented in one of the first or
second directions of the woven pattern float under one or more
successive yarns oriented in the other of said first or second
directions.
The systematically distributed surface areas of predetermined
configuration can have a variety of different weave patterns
therein, as desired. In fact, different systematically distributed
surface areas within a fabric can have different weave patterns to
thereby provide areas that sit at different heights, or in
different planes, within the fabric. Moreover, in the most
preferred embodiments of the invention opposed edges of the yarns
in the lattice define the perimeter, and therefore the
configuration, of adjacent, spaced-apart, systematically
distributed surface areas.
In certain embodiments the systematically distributed surface areas
are of a low yarn interlacing density; being provided by successive
yarns oriented in one of the first and second directions floating
over two or more successive yarns oriented in the other of said
first and second directions; these latter floats predominating the
weave pattern in the systematically distributed surface areas. In
fact, in accordance with certain embodiments of the invention the
yarn interlacing density is zero, i.e., there are no interlacings
within the body of the systematically distributed areas; the
interlacings only occurring at margins of such areas.
In accordance with the broadest aspects of this invention, the
systematically distributed areas do not need to be of a low yarn
interlacing density, and can be of a high yarn interlacing density,
such as a plain weave.
In accordance with certain preferred embodiments of this invention
the systematically distributed surface areas that are predominately
of a low yarn interlacing density provided by successive yarns
oriented in one of the first and second directions of the weave
pattern floating over two or more successive yarns oriented in the
other of said first and second directions include an area therein
wherein one or more of the successive yarns oriented in said one of
the first and second directions interlaces with at least one yarn
oriented in the other of said first and second directions to
thereby interrupt the continuity of the yarn float over the yarns
oriented in the other of said first and second directions. But for
such interruption the yarn interlacing density would be zero.
In accordance with this invention the yarn types, cross-sectional
areas, polymers, shapes, shrinkages, etc. employed in the fabrics,
as well as their distribution throughout the fabrics, can be
varied. For example, single multi filament or monofilament yarns in
either the weft and or the warp systems may be replaced by paired
yarns that follow identical weave paths. Conversely, where paired
groupings occur naturally in the weave, these may be replaced with
a thinner or thicker yarn to influence the yarn density.
Yarns of various diameters may be used selectively in weft and/or
warp groups by grouping or alternations or otherwise to enhance the
shaping effect on the formed sheets.
Equal diameter yarns may be paired, or yarns with different
diameters can be paired together to reduce yarn crossover/twist
during seaming of flat woven fabric; it being understood that
seaming is not an issue in tubular woven fabrics in accordance with
this invention. Pairs of profiled (i.e., non-circular
cross-section) yarns preferably having engaging profiles, e.g., a
round yarn paired with a profiled yarn having a profiled depression
in the side adjacent the round yarn may be used. Such engaged
profiled yarns hold together better to prevent twisting during
seaming. These yarns lie roughly side-by-side rather than on top
(i.e., over or under)of each other.
Shaping may alternatively be enhanced by using yarns having a
significant difference in heat shrinkage values, for instance by
alternating, grouping or otherwise distributing yarns in weft
and/or warp groups to enhance the shaping effect.
For example one set of warp or weft yarns may have a shrinkage of
1-5%, and the other set of warp or weft yarns may have a shrinkage
10-20%. This difference of shrinkage distorts the fabric structure
at an angle perpendicular to the plane of the fabric, leading to
raised floats and/or knuckles that physically shape the sheet.
In other embodiments the yarns can be crimped at an angle
perpendicular to the plane of the fabric to provide or enhance the
height of the raised floats and/or knuckles that physically shape
the sheet.
To alter drainage characteristics of the fabric some or all of the
warp and/or weft yarns can be laterally crimped within the plane of
the fabric.
Bicomponent yarns with differential shrinkage in the components,
whether core and sheath, twisted or parallel bicomponent multi
filaments may be used. The significant difference in shrinkage for
monofilament yarns may be achieved using identical or different
polymer family materials.
Shrinkage may be brought about by heat setting the fabric, and/or
treating the fabric in a hot liquid, such as boiling water.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of fabrics according to this invention will
now be described by way of example, with reference to the
accompanying drawings, wherein:
FIG. 1 is a weave pattern diagram of one repeat of a first
embodiment of a forming fabric according to the invention;
FIGS. 2A and 2B are sectional views showing the paths of selected
weft yarns in one pattern repeat of FIG. 1;
FIG. 3 is a weave pattern diagram of the first embodiment
illustrated in FIG. 1, but showing more than a single repeat;
FIG. 4 is a weave pattern diagram of a second embodiment of a
forming fabric according to the invention;
FIG. 5 is a weave pattern diagram of a third embodiment of a
forming fabric according to the invention;
FIG. 6 is a weave pattern diagram of a fourth embodiment of a
forming fabric according to the invention;
FIG. 7 is a weave pattern diagram of a fifth embodiment of a
forming fabric according to the invention;
FIG. 8 is a weave pattern diagram of a sixth embodiment of a
forming fabric according to the invention;
FIG. 9 is a weave pattern diagram of a seventh embodiment of a
forming fabric according to the invention;
FIG. 10 is a weave pattern diagram of an eighth embodiment of a
forming fabric according to the invention;
FIG. 11 is a weave pattern diagram of an ninth embodiment of a
forming fabric according to the invention;
FIG. 12 is a weave pattern diagram of an tenth embodiment of a
forming fabric according to the invention; and
FIG. 13 is a weave pattern diagram of a eleventh embodiment of a
forming fabric according to the invention.
BEST MODES OF THE INVENTION
Referring to FIGS. 1 and 3, a fabric in accordance with a first
embodiment of this invention is shown at 8, and includes a 10 warp
by 10 weft yarn repeat pattern. Shaded squares each show where the
respective weft thread, number 1 to 10 is woven below the
respective warp thread number 1 to 10, and unshaded squares
indicate that the weft thread is floated over the warp thread on
the web contacting surface of the fabric.
It should be understood that for some forming, transferring and/or
through drying applications the weave pattern can be reversed. In
this latter case, the pattern of warp floats and weft floats will
be the opposite of that depicted in FIGS. 1 and 3. FIG. 1 shows a
single weave repeat of the embodiment. To understand how the
embossing pattern develops it is preferable to refer to FIG. 3
wherein a multitude of weave repeats is represented.
As is illustrated best in FIG. 3, the warp floats formed by the
interweaving define a continuous chain link-like lattice 31
surrounding systematically distributed diamond shaped surface areas
30. In the illustrated embodiment, each of the systematically
distributed diamond-shaped areas 30 includes eight weft yarns
floating continuously over eight warp yarns, i.e., the yarns in the
systematically distributed areas have an interlacing density of
zero. FIGS. 2A and 2B show sections of the fabric repeat, showing
selected yarn paths of weft threads relative to warp threads. In
FIG. 2A, weft yarn 1 (full line) is woven below warp yarns 1 and
10, whilst weft yarn 2 (dashed line) is woven below warp yarns 2
and 9, whilst weft yarn 3 (dotted line) is woven below warp yarns 3
and 8. In FIG. 2B the remaining weft yarns 4 (dashed line) and 5
(full line) are shown, woven under warp yarns 4 and 7; and 5 and 6
respectively. The remaining weft yarns 6-10 are disposed
symmetrically in mirror image formation to the weft yarns 1-5. Thus
100% of the warp yarns defining the perimeter of adjacent
systematically distributed areas have a zero interlacing
density.
Referring to FIG. 4, another embodiment of a fabric in accordance
with this invention is illustrated at 100. This fabric, as is the
case with all of the fabrics of this invention, can be employed in
machines for manufacturing non woven webs, as well as a forming
wire, a transfer wire and/or a TAD fabric in a papermaking, or
other wet forming machine or process. Referring to FIG. 4, the dark
areas are areas in which warp yarns float over weft yarns, and the
light areas are areas in which weft yarns float over warp yarns.
This fabric 100 is a 20 shaft, 20 pick weave. That is, the weave
pattern of the warp yarns repeats every twenty yarns, and the weave
pattern of the weft yarns repeats every twenty yarns.
Still referring to FIG. 4, the fabric 100 has a continuous chain
link-like lattice 102 on the depicted surface, which is provided by
warp floats of each of the warp yarns over more than one weft yarn,
and wherein the warp floats provided by each of the warp yarns at
least partially overlaps a warp float provided by an adjacent warp
yarn. In fact, the portion of the continuous lattice provided by
warp yarns 1 through 9 floating over weft yarns 1 through 20 is
provided by adjacent, partially overlapping warp floats of the
adjacent warp yarns. Likewise, the portion of the continuous
lattice provided by warp yarns 12 through 20 floating over weft
yarns 1 through 20 is provided by adjacent, partially overlapping
warp floats of the adjacent warp yarns. In this embodiment of the
invention, like the embodiment 8, 100% of the yarns in the
continuous lattice that define the marginal edges of adjacent
systematically distributed surface areas 104 have a zero
interlacing density.
To further explain, within a single weave repeat, the continuous
lattice 102 is provided by warp floats of varying length. Each warp
yarn 1 and 20 floats over weft yarns 1 and 2, and also over weft
yarns 19 and 20. Adjacent portions of the continuous lattice are
provided by warp floats of warp yarns 2 and 19 over weft yarns 1
through 3 and also over weft yarns 18 through 20. Thus, the warp
floats of warp yarns 2 and 19 over weft yarns 1 through 3 partially
overlap the warp floats of warp yarns 1 and 20 over weft yarns 1
and 2, respectively. Likewise, the warp floats of warp yarns 2 and
19 over weft yarns 18 through 20 partially overlap the warp floats
of warp yarns 1 and 20 over weft yarns 19 and 20, respectively.
Still referring to FIG. 4, the continuous lattice 102 defines, or
separates, a plurality of systematically distributed surface areas
104 of a configuration determined by the configuration of the
continuous lattice. As illustrated, each systematically distributed
area 104 bound by the continuous lattice 102 is essentially
diamond-shaped and includes sixteen successive yarns in each of the
warp and weft directions.
Within each systematically distributed area 104 is a smaller
diamond-shaped area 106 bound by a diamond-shaped pattern of warp
floats 108 provided by a group of adjacent warp yarns interrupting
weft floats that are provided by a group of adjacent weft yarns. In
the center of each of the smaller diamond-shaped areas 106 is an
area provided by adjacent warp yarns (e.g., 10, 11) floating over a
pair of adjacent weft yarns (e.g., 1, 20).
Referring to FIG. 5, an additional embodiment of a fabric in
accordance with this invention is illustrated at 200. In
particular, the dark areas are areas in which warp yarns float over
weft yarns, and the light areas are areas in which weft yarns float
over warp yarns. This fabric 200, like the fabric 100, is a 20
shaft, 20 pick weave. That is, the weave pattern of the warp yarns
repeats every twenty yarns, and the weave pattern of the weft yarns
repeats every twenty yarns.
Still referring to FIG. 5, the chain link 4 like lattice 202 on the
depicted surface is continuous. In particular, the continuous
lattice 202, like the continuous lattice 102 (FIG. 4), has an
interlacing density of zero and is provided by warp floats of each
of the warp yarns over more than one weft yarn; wherein the warp
floats provided by each of the warp yarns at least partially
overlaps a warp float provided by an adjacent warp yarn. In fact,
the portion of the continuous lattice provided by warp yarns 1
through 9 floating over weft yarns 1 through 20 is provided by
adjacent, partially overlapping warp floats of the adjacent warp
yarns. Likewise, the portion of the continuous lattice provided by
warp yarns 12 through 20 floating over weft yarns 1 through 20 is
provided by adjacent, partially overlapping warp floats of the
adjacent warp yarns.
To further explain, within a single repeat, a portion of the
continuous lattice 202 is provided by warp floats of each of warp
yarns 1 and 20 over weft yarns 1 and 2, and also over weft yarns 19
and 20. Adjacent portions of the continuous lattice are provided by
warp floats of warp yarns 2 and 19 over weft yarns 1 through 3 and
also over weft yarns 18 through 20. Thus, the warp floats of warp
yarns 2 and 19 over weft yarns 1 through 3 partially overlap the
warp floats of warp yarns 1 and 20 over weft yarns 1 and 2,
respectively. Likewise, the warp floats of warp yarns 2 and 19 over
weft yarns 18 through 20 partially overlap the warp floats of warp
yarns 1 and 20 over weft yarns 19 and 20, respectively.
Still referring to FIG. 5, the continuous lattice defines, or
separates, a plurality of systematically distributed surface areas
204 of a predetermined configuration. As illustrated, each
systematically distributed area 204 bound by the lattice is
essentially diamond-shaped and includes sixteen successive yarns in
both the warp and weft directions.
Within each systematically distributed area 204 is a smaller,
essentially diamond-shaped area 206 bound by an essentially
diamond-shaped pattern of warp floats 208 provided by a group of
adjacent warp yarns interrupting weft floats that are provided by a
group of adjacent weft yarns. The continuity of the essentially
diamond-shaped pattern of warp floats 208 is interrupted by the
omission of warp floats at the opposed transverse ends of the
pattern. For example, warp yarns 6 and 15 do not provide any warp
floats within the systematically distributed areas 204 to close the
diamond configuration of the warp floats 208.
In the center of each of the smaller, essentially diamond-shaped
areas 206 is an area provided by overlapping warp floats.
Specifically, warp yarns 19, 20 and 1 float over weft yarn 10 and
warp yarns 20, 1 and 2 float over weft yarn 11. Thus, adjacent warp
yarns 20 and 1 float over adjacent weft yarns 10 and 11.
Referring to FIG. 6, an additional embodiment of a fabric in
accordance with this invention is illustrated at 300. In
particular, the dark areas are areas in which warp yarns float over
weft yarns, and the light areas are areas in which weft yarns float
over warp yarns. This fabric is a 10 shaft, 8 pick weave. That is,
the weave pattern of the warp yarns repeats every 10 yarns, and the
weave pattern of the weft yarns repeats every 8 yarns.
Still referring to FIG. 6, the chain link-like lattice 302 on the
depicted surface is continuous and has an interlacing density of
zero. This continuous lattice 302, within each repeat, is provided
by warp floats of each of the warp yarns over a single weft yarn,
and wherein the warp floats provided by each of the warp yarns are
immediately adjacent a warp float provided by an adjacent warp
yarn. Specifically, the portion of the continuous lattice provided
by warp yarns 1 through 5 floating over weft yarns 1 through 8 is
in the form of diagonally converging lines 301, 303 of adjacent and
warp floats, with the warp float provided by warp yarn 5 passing
over weft yarn 5 being common to both lines. Likewise, the portion
of the continuous lattice provided by warp yarns 6 through 10
floating over weft yarns 1 through 8 is in the form of diagonally
diverging lines 305, 307 of adjacent and warp floats, with the warp
float provided by the warp yarn 6 passing over the weft yarn 5
being common to both lines.
Still referring to FIG. 6, the continuous lattice 302 defines, or
separates, a plurality of systematically distributed surface areas
304 of a predetermined configuration. As illustrated, each
systematically distributed area 304 bound by the lattice is
essentially diamond-shaped, and is defined predominately by weft
yarns floating over warp yarns. In fact, except for the weft floats
being interrupted by two adjacent warp yarns (e.g., 1 and 10)
floating over the same single weft yarn (e.g., 5), each of the
systematically distributed surface areas 304 is provided entirely
by weft yarns floating over warp yarns. In this embodiment each
area 304 includes eight successive warp yarns and seven successive
weft yarns.
Referring to FIG. 7, another embodiment of a fabric in accordance
with this invention is illustrated at 400. In particular, the dark
areas are areas in which warp yarns float over weft yarns, and the
light areas are areas in which weft yarns float over warp yarns.
This fabric is a 10 shaft, 10 pick weave. That is, the weave
pattern of the warp yarns repeats every 10 yarns, and the weave
pattern of the weft yarns repeats every 10 yarns.
Still referring to FIG. 7, chain link-like lattice 402 on the
depicted surface is continuous with an interlacing density of zero.
This continuous lattice 402 is provided by warp floats of each of
the warp yarns over more than one weft yarn, and wherein the warp
floats provided by each of the warp yarns at least partially
overlaps a warp float provided by an adjacent warp yarn. In fact,
the portion of the continuous lattice provided by warp yarns 1
through 5 floating over weft yarns 1 through 10 is provided by
adjacent, overlapping warp floats of the adjacent warp yarns.
Likewise, the portion of the continuous lattice provided by warp
yarns 6 through 10 floating over weft yarns 1 through 10 is
provided by adjacent, overlapping warp floats of the adjacent warp
yarns.
To further explain, within a single weave repeat, a portion of the
continuous lattice 402 is provided by warp floats of each of warp
yarns 1 and 10 over weft yarn 1, and also over weft yarns 9 and 10.
Adjacent portions of the continuous lattice are provided by warp
floats of warp yarns 2 and 9 over weft yarns 1 and 2, and also over
weft yarns 8 and 9. Thus, the warp floats of warp yarns 2 and 9
over weft yarns land 2 partially overlap the warp floats of warp
yarns 1 and 10 over weft yarn 1, respectively. Likewise, the warp
floats of warp yarns 2 and 9 over weft yarns 8 and 9 partially
overlap the warp floats of warp yarns 1 and 10 over weft yarns 9
and 10, respectively.
Still referring to FIG. 7, the continuous lattice 402 defines, or
separates, a plurality of systematically distributed surface areas
404 of a predetermined configuration. As illustrated, each
systematically distributed area 404 bound by the lattice 402 is
essentially diamond-shaped and includes eight warp yarns and seven
weft yarns.
Each of the systematically distributed areas 404 is dominated by
weft floats. In fact; except for warp floats provided by two
adjacent warp yarns (e.g., 5, 6) floating over a single weft yarn
(e.g., 10) each of the systematically distributed areas 404 is
provided by weft floats. This results in the systematically
distributed areas 404 being of a low yarn interlacing density.
Referring to FIG. 8, another embodiment of a fabric in accordance
with this invention is illustrated at 500. In particular, the dark
areas are areas in which warp yarns float over weft yarns, and the
light areas are areas in which weft yarns float over warp yarns.
This fabric is a 10 shaft, 8 pick weave. That is, the weave pattern
of the warp yarns repeats every 10 yarns, and the weave pattern of
the weft yarns repeats every 8 yarns.
Still referring to FIG. 8, chain link-like lattice 502 is continues
and has an interlacing density of zero. This continuous lattice 502
on the depicted surface is provided by warp floats of each of warp
yarns 2, 3, 8 and 9 over single, spaced apart weft yarns, and by
warp floats of each of warp yarns 1, 4 through 7 and 10 over a pair
of adjacent weft yarns. Specifically, the portions of the
continuous lattice provided by warp yarns 1 through 4 floating over
weft yarns 1 through 8 are aligned in diagonally converging lines
501, 503. Likewise, the portions of the continuous lattice provided
by warp yarns 7 through 10 floating over weft yarns through 8 are
aligned in diagonally diverging lines 505, 507. In addition, warp
yarns 4 through 7 each float over weft warns 4 and 5 to form a
rectangular array of warp floats.
Referring to FIG. 9, yet another embodiment of a fabric in
accordance with this invention is illustrated at 600. In
particular, the dark areas are areas in which warp yarns float over
weft yarns, and the light areas are areas in which weft yarns float
over warp yarns. This fabric is a 5 shaft, 6 pick weave. That is,
the weave pattern of the warp yarns repeats every 5 yarns, and the
weave pattern of the weft yarns repeats every 6 yarns.
Still referring to FIG. 9, a chain link-like lattice 602 is
continuous and has in interlacing density of zero. This continuous
lattice 602 on the depicted surface is provided by warp floats of
each of warp yarns 2 and 4 over single, spaced apart weft yarns,
and by a warp float of warp yarns 1, 3 and 5 over a pair of
adjacent weft yarns. Specifically, warp yarns 1 and 5 float over
weft yarns 1 and 6; warp yarns 2 and 4 float over weft yarns 2 and
5 and warp yarn 3 floats over weft yarns 3 and 4.
Still referring to FIG. 9, the continuous lattice 602 defines, or
separates, a plurality of systematically distributed surface areas
604 and 606, which are of a configuration determined by the lattice
arrangement. As illustrated, it should be apparent that the
systematically distributed surface areas 604 bound by the lattice
are defined by four weft yarns floating over four warp yarns,
whereas the systematically distributed surface areas 606 are of a
different size, being defined by four waft yarns floating over
three warp yarns.
Referring to FIG. 10, yet another embodiment of a fabric in
accordance with this invention is illustrated at 700. In
particular, the dark areas are areas in which warp yarns float over
weft yarns, and the light areas are areas in which weft yarns float
over warp yarns. This fabric is a 20 shaft, 14 pick weave. That is,
the weave pattern of the warp yarns repeats every 20 yarns, and the
weave pattern of the weft yarns repeats every 14 yarns.
Still referring to FIG. 10, a chain link-like lattice 702 is
continuous and has an interlacing density of zero. This continuous
lattice 702 defines, or separates, a plurality of systematically
distributed surface areas 704 which are of a an essentially
diamond-shaped configuration determined by the arrangement of the
continuous lattice. As illustrated, it should be apparent that the
systematically distributed surface areas 704 bound by the lattice
are defined by a high interlacing density, plain weave pattern
including nine weft yarns interlacing with nine warp yarns.
Referring to FIG. 11, yet another embodiment of a fabric in
accordance with this invention is illustrated at 800. In
particular, the dark areas are areas in which warp yarns float over
weft yarns, and the light areas are areas in which weft yarns float
over warp yarns. This fabric is a 20 shaft, 28 pick weave. That is,
the weave pattern of the warp yarns repeats every 20 yarns, and the
weave pattern of the weft yarns repeats every 28 yarns.
Still referring to FIG. 11, a chain link-like lattice 802 is
continuous and has an interlacing density of zero. This continuous
lattice 802 defines, or separates, a plurality of systematically
distributed surface areas 804 and 806, which are of an essentially
diamond-shaped configuration determined by the arrangement of the
continuous lattice, but differing in interlacing density. As
illustrated, it should be apparent that the systematically
distributed surface areas 804 defined by the lattice are areas of a
high interlacing density, plain weave pattern including nine weft
yarns interlacing with nine warp yarns, and the systematically
distributed surface areas 806 are defined by a zero interlacing
density pattern including nine warp yarns floating over nine weft
yarns. The yarns in the systematically distributed surface areas
having different interlacing densities will sit at different
levels, thereby imparting, or creating a multilevel shape or
pattern in the formed web.
Referring to FIG. 12, yet another embodiment of a fabric in
accordance with this invention is illustrated at 900. In
particular, the dark areas are areas in which warp yarns float over
weft yarns, and the light areas are areas in which weft yarns float
over warp yarns. This fabric is a 20 shaft, 16 pick weave. That is,
the weave pattern of the warp yarns repeats every 20 yarns, and the
weave pattern of the weft yarns repeats every 16 yarns.
Still referring to FIG. 12, a lattice 902 is interrupted to provide
a plurality of discrete segments in the form of discontinuous
lattice areas 902a, each having an interlacing density of zero.
Each of the discontinuous lattice areas 902a has a zig-zag, or
herringbone-configured area that extends in the weft direction and
is spaced apart from adjacent lattice areas 902a in the warp
direction. Pairs of adjacent, spaced-apart lattice areas 902a
define, or separate, a plurality of systematically distributed
surface areas, e.g., 904 and 906. In other words, a pair of
adjacent, spaced-apart lattice areas 902a is required to define the
entire outer margin or perimeter of each systematically distributed
surface area 904 and 906. As illustrated, it should be noted that
the systematically distributed surface areas 904 and 906 have weave
patterns that differ from each other, and also from the zero
interlacing pattern of the adjacent lattice areas 902. This
creates, or provides, areas of different heights, or levels in the
fabric, that, likewise, create a multilevel pattern in the webs
formed with the use of the fabric 900.
Referring to FIG. 13, yet another embodiment of a fabric in
accordance with this invention is illustrated at 950. In
particular, the dark areas are areas in which warp yarns float over
weft yarns, and the light areas are areas in which weft yarns float
over warp yarns. This fabric is a 20 shaft, 20 pick weave and is
very similar to the fabric 100 illustrated in FIG. 4. In fact, the
fabric 950 has a chain link-like lattice 952 defining
systematically distributed surface areas 954 that are identical to
the surface areas 104 of the fabric 100.
The fabric 950 differs from the fabric 100 solely in the
arrangement of the lattice 952. Specifically, the lattice 952
differs from the lattice 102 of fabric 100 in that the continuous
float of the weave pattern in 40% of the yarns (i.e., 8 of the 20
warp yarns in each repeat of the weave pattern) of the lattice 952
is interrupted so that 40% of the yarns have an interlacing density
greater than zero. As illustrated, within each weave repeat weft
yarn 1 passes over warp yarn 1, weft yarn 3 passes over warp yarns
3 and 18, weft yarn 7 passes over warp yarns 7 and 14, weft yarn 10
passes over warp yarn 10, weft yarn 11 passes over warp yarn 11,
weft yarn 14 passes over warp yarns 7 and 14, weft yarn 18 passes
over warp yarns 3 and 18 and weft yarn 20 passes over warp yarn 20
to thereby interrupt the continuity of the float of 40% of the
yarns in the lattice 952.
As noted earlier in this application, the fabrics of this invention
can be used in a variety of web forming operations; both wet and
dry. Moreover, the fabrics of this invention may be used to
provided different functions within the web forming process. For
example, the fabric may be employed as a forming wire in a wet
sheet forming process; as a transfer fabric in such a process
and/or as a dryer fabric in such a process.
It also should be noted that in all of the illustrated embodiments
the shaded areas represent warp yarns floating over weft yarns. It
should be understood that this arrangement can be reversed, with
the shaded areas depicting weft yarns passing over warp yarns.
It also should be noted that the weave pattern within each
systematically distributed area can be varied within the broadest
aspects of this invention. Thus, although the embodiments
illustrated herein include systematically distributed areas of low
yarn interlacing density, it is within the scope of this invention
to vary the weave pattern with the systematically distributed areas
to provide high yarn interlacing density regions therein.
Also, the pattern, or configuration, of the continuous lattice and
of the systematically distributed areas can be varied; the specific
pattern not constituting a limitation on the broadest aspects of
this invention.
In certain applications, the continuous lattice is provided by high
knuckles and the fabric is employed to emboss, or compress the
formed sheet to enhance the strength of the formed sheet in all
directions.
In accordance with this invention the spacing of the weft yarns may
be varied by intermittent activation of devices such as direct DC
loom drive, and AC servo drives for warp yarn let off and fabric
take up. In addition the order of reed denting may be varied to
enhance warp yarn groupings.
Without further elaboration, the foregoing will so fully illustrate
my invention that others may, by applying current or future
knowledge, adapt the same for use under various conditions of
service.
* * * * *